JP4796571B2 - Chemical lace base fabric and method for producing the same - Google Patents

Description

  The present invention relates to a base fabric for chemical lace that is soft, has high dimensional stability, has a low melting temperature, and is inexpensive.

Conventionally, a woven fabric made of water-soluble polyvinyl alcohol (hereinafter referred to as PVA) long fibers has been mainly used as a base fabric for chemical lace. Although this woven fabric has high dimensional stability, it is difficult for the embroidery pattern to be displaced, and the base fabric can be dissolved and removed at a relatively low temperature, but on the other hand, the long fibers themselves are expensive and special weaving. Since a process is required, there is a problem that it is extremely expensive. In addition, since it is a woven fabric, the fabric is hard, and there is also a drawback that needle breakage easily occurs during embroidery.
In recent years, the chemical race market has continued to grow steadily as demand in other countries, particularly in Asia, expands. The demand trend has shifted from those mainly composed of post-dyed embroidery threads to those that are colorful dyed-dyed rayon and dyed-dyed embroidery threads. Above all, pre-dyed polyester embroidery yarns using disperse dyes are environmentally friendly because recycled polyester can be used, and their gloss, durability and washing durability are excellent, and their use tends to increase.
In the future, there is an increasing demand for base fabrics that can be dissolved and removed at temperatures below 80 ° C to prevent dye transfer from pre-dyed polyester embroidery yarns, are inexpensive, have good workability, are soft, have high dimensional stability, and do not easily dislocate embroidery patterns. Expected to increase.

  A water-soluble nonwoven fabric is used as a base fabric to replace the expensive water-soluble woven fabric as described above, and various attempts using such a nonwoven fabric have been made so far. For example, a nonwoven fabric made of PVA fibers having a melting temperature in water of 10 ° C. or less and heat-fusible has been proposed (for example, see Patent Document 1). However, such special fibers are expensive because of low productivity. Further, if the embossed adhesive area ratio of the nonwoven fabric is increased, dimensional stability at the time of embroidery can be ensured, but on the other hand, the softness is impaired and needle breakage occurs at the time of embroidery. For this reason, dimensional stability at the time of embroidery is ensured by providing a relatively high basis weight, but it is difficult to provide a base fabric with excellent quality.

  Moreover, the embossed nonwoven fabric of the PVA type | system | group spun bond web is proposed (for example, refer patent document 2). Although this production method is suitable for mass production, it is necessary to reduce the degree of polymerization of the raw material resin for the stability of spinning, and it is difficult to perform orientation crystallization sufficiently by heat treatment, and it is difficult to achieve dimensional stability. It was difficult to obtain a good base fabric.

  Furthermore, what joined the random web nonwoven fabric and the cloth-like material with the water-soluble adhesive etc. is proposed (for example, refer patent document 3). However, in order to obtain such a cloth-like product, it is necessary to introduce special equipment, and it has been difficult to provide a general-purpose and inexpensive base fabric.

  On the other hand, as a base fabric with good dimensional stability, there are many cases in which random webs made of PVA fibers are bonded with a binder aqueous solution containing a water-soluble resin. For example, a PVA long fiber web is bonded with the binder aqueous solution. A non-woven fabric has been proposed (see, for example, Patent Document 4). However, in order to produce a nonwoven fabric using PVA-based long fibers, the production process has to be discontinuous, and it has been difficult to supply a general-purpose and inexpensive base fabric. Furthermore, when a base fabric bonded with an aqueous binder solution containing a water-soluble resin is subjected to heat treatment, there is a problem that shrinkage increases.

  As a method other than the above, it has been proposed to spray or impregnate a PVA-based fiber entangled sheet with an aqueous binder solution and perform tension treatment in the width direction during drying (see, for example, Patent Document 5). However, since this method requires a relatively large amount of binder resin to be adhered, it has been difficult to satisfy dimensional stability and softness at the same time. Furthermore, when applied to a low-melting type PVA fiber which can use pre-dyed polyester embroidery thread which is likely to transfer, it is difficult to obtain a base fabric with good texture due to swelling and shrinkage caused by water.

JP 11-217759 A JP 2001-279568 A JP 2003-129383 A Japanese Patent Application Laid-Open No. 7-054257 JP-A-1-018182

As described above, there are many obstacles to practical use in obtaining an inexpensive chemical lace base fabric that is soft, has high dimensional stability, and has a low melting temperature. Development of a base fabric was desired.
An object of the present invention is to provide an inexpensive chemical lace base fabric that is soft, has good workability, has high dimensional stability, hardly causes embroidery pattern skipping / displacement, and has a low melting temperature, and a method for producing the same.

  In order to achieve the above-mentioned problems, the present inventors have made extensive studies, and as a result, a random web composed of water-soluble PVA fibers and a binder containing an aqueous solution containing a PVA resin (hereinafter simply referred to as foam). It was found that an inexpensive, soft, high dimensional stability and low melting temperature chemical lace base fabric can be obtained by impregnating and drying a binder aqueous solution. This processing method that provides the aqueous binder solution is simple and versatile, and can reduce the amount of moisture adhering compared to conventional spraying and impregnation methods. And the energy required for drying can be saved, which meets the problems of the present invention. Furthermore, this processing method, which provides a foam-like binder, concentrates the binder resin in the aqueous binder solution at the fiber entangled part compared to the conventional method, so high dimensional stability can be obtained with a relatively small amount of binder resin. The present inventors have found that there is an advantage that the softness of the base fabric is not impaired, and the present invention has been completed.

That is, the present invention is a chemical lace base fabric comprising a random web nonwoven fabric of water-soluble PVA fibers and a pre-dyed embroidery thread and satisfying all the following conditions.
(1) The binder to be adhered to the nonwoven fabric is a foamed aqueous solution containing a PVA resin, and the adhesion amount of the binder with respect to the total nonwoven fabric mass is 2 to 20% by mass,
(2) The 10% modulus strength in the horizontal direction of the nonwoven fabric is 15 to 80 N / 50 mm width,
(3) The bending resistance of the nonwoven fabric is 40 to 150 mm.

  In the present invention, preferably, when the water-soluble dissolution temperature of the water-soluble vinyl alcohol fiber constituting the nonwoven fabric is A ° C. and the water dissolution temperature of the random web nonwoven fabric of the polyvinyl alcohol fiber is B ° C., B−A ≦ The base fabric for chemical lace as described above, which is 5 ° C.

  Furthermore, the above-mentioned chemical lace base fabric is preferably characterized in that the PVA fiber constituting the nonwoven fabric has a water dissolution temperature of 50 to 80 ° C.

  According to the present invention, it is possible to provide an inexpensive chemical lace base fabric that is soft and has good workability, has high dimensional stability, is unlikely to cause embroidery pattern skipping and displacement, and has a low melting temperature, and a method for manufacturing the same. .

  In the present invention, it is necessary to use a water-soluble PVA polymer as the resin constituting the fiber. In the case of a so-called partially saponified PVA in which the units other than the vinyl alcohol unit are vinyl acetate units as the water-soluble PVA-based polymer used in the present invention, The saponification degree of the partially saponified PVA is preferably 95 to 99.95 mol%. When it exceeds 99.95 mol%, crystallization proceeds during dry heat stretching or dry heat shrinkage, and the dissolution temperature in water may exceed 80 ° C.

  When a so-called modified PVA containing a unit other than a vinyl alcohol unit and a vinyl acetate unit is used, when the modified unit is a unit having a large crystallization inhibitory effect, the modified unit has a modified unit of about 0.5 mol%. Even if it is a polymer, it may be suitably used in the present invention, but in general, it is preferable to use a modified PVA polymer having a modified unit of 1 mol% or more. In the case of a modified PVA polymer, even if the degree of saponification is higher than that of an unmodified PVA polymer, the dissolution temperature in water can be lowered due to its crystal inhibition effect. On the other hand, if the modifying unit exceeds 20 mol%, the crystallinity is significantly lowered, and not only the fiber physical properties are lowered, but also the spinnability is lowered.

  Monomers forming the modifying unit include ethylene, allyl alcohol, itaconic acid, acrylic acid, vinylamine, maleic anhydride and its ring-opened product, sulfonic acid-containing vinyl compounds, vinyl pivalate and 4 or more carbon atoms. Examples thereof include fatty acid vinyl esters, vinyl pyrrolidone, and compounds obtained by neutralizing part or all of the ionic groups. The method for introducing the modified unit may be a copolymerization method or a post-reaction introduction method. The distribution of the modified units within the polymer chain is not particularly limited, whether it is random, block or graft. Further, the degree of polymerization of the polymer is not particularly limited, but the degree of polymerization is preferably 1000 or more, particularly preferably 1500 or more from the viewpoint of mechanical performance and versatility of the fiber, and is 4000 or less from the viewpoint of fiber spinnability. Is preferred.

Next, the manufacturing method of the PVA type fiber of this invention is demonstrated.
In the present invention, fibers having excellent mechanical performance and water solubility can be efficiently obtained by producing fibers using a spinning stock solution in which a water-soluble PVA polymer is dissolved in water or an organic solvent. Of course, additives and polymers other than those described above may be contained in the spinning dope as long as the effects of the present invention are not impaired. Examples of the solvent constituting the spinning dope include water, polar solvents such as dimethyl sulfoxide (DMSO), dimethylacetamide, dimethylformamide, and N-methylpyrrolidone, polyhydric alcohols such as glycerin and ethylene glycol, and these solvents and rhodan. Examples include salts, mixtures of swellable metal salts such as lithium chloride, calcium chloride, and zinc chloride, and mixtures of these solvents, or mixtures of these solvents and water. Among these, water and DMSO are low temperature. It is most suitable in terms of solubility, low toxicity, low corrosivity and the like.
The polymer concentration in the spinning dope varies depending on the composition, polymerization degree, and solvent, but is preferably in the range of 8 to 40% by mass. The liquid temperature at the time of discharging the spinning stock solution is in a range where the spinning stock solution is not gelled, decomposed or colored, and is preferably in the range of 50 to 150 ° C.

  Such spinning dope may be discharged from a nozzle to perform wet spinning or dry / wet spinning, and may be discharged into a solidified liquid having a solidifying ability for the PVA polymer. In particular, when the spinning solution is discharged from multiple holes, the wet spinning method is more preferable than the dry and wet spinning method from the viewpoint of preventing sticking of fibers during discharging. The wet spinning method is a method in which the spinning stock solution is discharged directly from the spinneret into the solidification bath, while the dry and wet spinning method is a method in which the spinning stock solution is discharged from the spinneret into air or inert gas once. And then into the solidification bath.

The solidification bath differs depending on whether the stock solution is an organic solvent or water. In the case of a stock solution using an organic solvent, a mixed solution consisting of a solidified solvent and a stock solution solvent is preferable from the viewpoint of fiber strength and the like obtained. As the solidified solvent, alcohols such as methanol and ethanol, and ketones such as acetone and methyl ethyl ketone. An organic solvent having a solidifying ability with respect to the PVA polymer, such as an organic solvent composed of methanol and DMSO is preferable, and a mass ratio of the solidifying solvent / stock solution solvent in the solidifying bath is 25/75 to 95/5, preferably A mixed solution of 55/45 to 80/20 is preferable in terms of spinning processability and solvent recovery. The temperature of the solidification bath is preferably 30 ° C. or lower, and in particular for uniform cooling gelation, it is 20 ° C. or lower, more preferably 15 ° C. or lower.
On the other hand, when the spinning dope is an aqueous solution, examples of the solidification solvent constituting the solidification solution include aqueous solutions of inorganic salts having solidification ability with respect to the PVA polymer, such as sodium sulfate, sodium chloride, and sodium carbonate. . Of course, this solidification bath may be either acidic or alkaline.

  Next, the solvent of the spinning dope is extracted and removed from the solidified shinoshino. It is preferable to wet-draw the thread Shino during extraction in order to suppress interfiber sticking during drying and to further increase the strength of the resulting fiber. The wet draw ratio is preferably 1.5 to 6 times. Extraction is usually performed by passing through a plurality of extraction baths. As the extraction bath, a solidified solvent alone or a mixed solution of a solidified solvent and a stock solvent is used, and the temperature of the extraction bath is usually in the range of 0 to 50 ° C.

  Then, if necessary, an oil agent or the like may be applied and dried. The drying temperature is preferably 210 ° C. or lower. In particular, multistage drying in which drying is performed at a low temperature of 160 ° C. or lower in the initial stage of drying and drying at a high temperature in the latter half of drying is preferable. Furthermore, dry heat stretching and, if necessary, dry heat shrinkage are performed, the PVA molecular chains are oriented and crystallized, and the strength, water resistance and heat resistance of the fiber are adjusted. In order to improve the mechanical performance of the fiber, it is preferable to carry out dry heat drawing under a temperature condition of 150 to 250 ° C. so that the total draw ratio is 3 times or more, particularly 5 times or more. By setting the total draw ratio to 3 times or more, it becomes possible to obtain a fiber having a strength of 1.5 to 4.0 cN / dtex and further to setting the total draw ratio to 5 times or more, a strength of 4 cN / dtex or more. The total draw ratio referred to in the present invention is a ratio represented by the product of the wet heat draw ratio and the dry heat draw ratio.

  Further, crimping is performed by applying an oil or the like as necessary. Conventionally known methods are used as the crimping method, but in order to impart sufficient crimp to the PVA fiber, dry heat preheating is performed in advance, introduced into a mechanical crimper, and crimped, Next, a method of firmly cooling the crimped form by cooling to below the glass transition temperature is suitable.

  Thus, it is preferable that the fineness of the fiber of this invention manufactured is 0.5-5 dtex. If it is less than 0.5 dtex, the fiber strength is insufficient and damage to the needle during embroidery increases. If it exceeds 5 dtex, the texture of the nonwoven fabric is deteriorated and the embroidery pattern skips and shifts, making it difficult to achieve good embroidery. More preferably, it is 1-3 dtex.

  The dissolution temperature in water of the PVA fiber used in the present invention is preferably 50 to 80 ° C. If the dissolution temperature in water is less than 50 ° C., swelling and shrinkage due to water are likely to occur, and shrinkage in the drying step after application of the resin binder aqueous solution becomes large, so that a nonwoven fabric with good texture cannot be obtained. This shrinkage during drying can be suppressed entirely by using a pin tenter or a sandwich net, but it is difficult to prevent local formation. On the other hand, if the fiber dissolution temperature in water exceeds 80 ° C., it is difficult to completely dissolve and remove the base fabric after embroidery, which is not preferable. More preferably, it is 55-75 degreeC.

Next, the manufacturing method of the nonwoven fabric which consists of PVA type fiber of this invention is demonstrated.
As the random web nonwoven fabric of the present invention, a dry nonwoven fabric in which the orientation of fibers constituting the nonwoven fabric is random is preferable, and a web created by a conventionally known card method or air raid method is used. In addition, as a method for randomizing the fiber orientation, a conventionally known cross wrap method or a criss cloth method is used. However, in the case of a chemical lace base fabric, a tension in the horizontal direction is applied particularly during embroidery. In order to suppress flying and deviation, it is preferable that the fiber orientation is random.

It is preferable that the fabric weight of the nonwoven fabric of this invention manufactured by the above-mentioned manufacturing method is 15-50 g / m < ² >. When the basis weight is less than 15 g / m ² , the number of fibers is reduced, the texture becomes uneven, and the embroidery pattern is likely to fly or shift. Moreover, since the strength of the base fabric itself is insufficient, the process passability during embroidery is extremely reduced. If the basis weight exceeds 50 g / m ² , not only will the price increase, but the softness of the nonwoven fabric will be impaired, so workability will be improved when connecting the base fabrics with a sewing machine or when spreading the base fabric to an embroidery machine. descend. Moreover, since the mass of the base fabric to be dissolved and removed increases, the melting and wastewater treatment costs increase, which is not preferable. More preferably, it is 20-40 g / m < ² >.

In the present invention, the nonwoven fabric obtained by the production method described above is impregnated with a foam-like binder and then subjected to a dry heat treatment, whereby a flexible and dimensional stability nonwoven fabric is obtained.
Furthermore, when the nonwoven fabric treated with the foam-like binder is embroidered with a pre-dyed embroidery thread, a chemical lace base fabric with less embroidery pattern jumping and misalignment can be obtained.
Here, the type of the dyed embroidery thread is not particularly limited, but polyester-based or rayon-based embroidery threads are preferably used.

As the binder to be attached to the nonwoven fabric of the present invention, a foamed aqueous solution containing a PVA resin is used. The foamed binder aqueous solution having the above composition is prepared by, for example, dissolving a PVA resin in water while stirring in a dissolver to prepare a PVA aqueous solution having a predetermined concentration, and then adding an auxiliary agent and a penetrating agent as necessary. It can be prepared by foaming by blowing air into the aqueous solution in the dissolver. For example, the prepared foam-like binder aqueous solution can be applied by allowing the foam-like binder aqueous solution to flow down from a nozzle onto a web made by the card method, or by bringing the web into contact with a roller with the foam-like binder aqueous solution on the surface. Impregnate and apply. In the present invention, by performing a dry heat treatment after impregnation and application, the binder resin in the aqueous binder solution tends to concentrate on the entangled portion of the fiber when the foam aqueous binder solution breaks, and the conventional spraying method or impregnation is performed. Equivalent adhesion can be obtained with a relatively small amount of resin adhesion compared to the conventional method. Therefore, there is an advantage that the softness of the nonwoven fabric, that is, the bending resistance described later, is easily ensured as compared with the conventional method in which the resin adheres in addition to the entangled portion of the fiber. Moreover, since the amount of water adhering to the nonwoven fabric is reduced, energy required for drying can be saved. Furthermore, when using low-melting-type PVA fibers that easily swell and shrink with water, the amount of moisture attached can be reduced, so swelling and shrinkage can be suppressed, and special devices such as pin tenters, sandwich nets, etc. Even if there is no, a base fabric with good formation can be obtained.
Further, by suppressing the swelling / shrinkage of the base fabric, the base fabric can obtain high strength even at a low elongation without impairing the strength and elongation properties of the fibers constituting the base fabric. Modulus strength can be easily obtained.

  The adhesion amount of the aqueous binder solution of the present invention is required to be 2 to 20% by mass with respect to the total mass of the nonwoven fabric. If it is less than 2% by mass, the adhesive strength with the nonwoven fabric is insufficient, and the strength required for the base fabric cannot be obtained. If the amount exceeds 20% by mass, the amount of resin adhering to the fiber other than the entangled portion increases, the nonwoven fabric softness is impaired, and at the same time, the strength of the nonwoven fabric reaches its peak, and the binder resin concentration increases. It becomes easy to cause trouble of winding. Preferably it is 3-17 mass%, More preferably, it is 4-15 mass%. The aqueous binder solution preferably contains a surfactant having a foaming / penetrating action. Examples of the surfactant include alkyl ether sulfonic acid type, dodecyl benzene sulfonic acid type, and castor oil sulfate. In addition to the surfactant, a softener, a pH adjuster, etc. may be added.

Subsequently, the drying process by dry heat is performed. Drying conditions by dry heat are not particularly limited, and examples include hot air drying and cylinder drying.
By performing such a dry heat treatment, it is possible to obtain a base fabric for chemical lace having an embroidery pattern that is flexible, has good dimensional stability, has a bright color, and has a high-quality feeling.

One of the most important qualities required for a base fabric for chemical lace is the 10% modulus strength in the horizontal direction. In general, embroidery is performed with a base cloth sandwiched between clips, etc. and stretched in the horizontal direction by several percent. At this time, what is required of the base cloth is not breaking strength, that is, the base cloth does not stretch during embroidery. The modulus strength is high. In the nonwoven fabric of the present invention, the 10% modulus strength in the horizontal direction must be 15 to 80 N / 50 mm width. If the 10% modulus strength in the horizontal direction is lower than 15 N / 50 mm width, the base fabric is stretched due to the tension during embroidery, and the embroidery pattern jumps and deviates, and precise embroidery cannot be obtained. On the other hand, if the 10% modulus strength in the horizontal direction exceeds 80 N / 50 mm width, there will be no problem of skipping or shifting of the embroidery pattern, but the flexibility of the nonwoven fabric will be lost, and the cloth and embroidery machine on the sewing machine between the base fabrics will be lost. Work efficiency such as spreading the base fabric on the table is extremely reduced. A preferable range of 10% modulus strength in the horizontal direction is 20 to 70 N / 50 mm width, and a more preferable range is 25 to 60 N / 50 mm width.
The 10% modulus strength in the vertical direction of the nonwoven fabric is not as important as the horizontal direction, but the 10% modulus strength is preferably 10 N / 50 mm width or more. If the 10% modulus strength in the vertical direction is too low, the fabric may be cut off in the vertical direction during embroidery extension, or trouble may occur during the shirring process after embroidery.

  Furthermore, the bending resistance of the nonwoven fabric of the present invention must be 40 to 150 mm. If it is less than 40 mm, the base fabric becomes too soft, and the embroidery pattern jumps or shifts during embroidery. Also, if it exceeds 150 mm, the base fabric becomes stiff, and work that requires softness of the base fabric, for example, bonding of a base fabric and a tulle sewing machine, introduction of a base fabric with a sewing machine or base fabric Workability such as spreading on an embroidery machine is remarkably lowered, and wrinkles are easily formed when the original fabric is wound after embroidery, and continuous preparation of the original fabric becomes difficult. The bending resistance of the nonwoven fabric is preferably 50 to 140 mm, more preferably 60 to 130 mm. In addition, the bending resistance of a nonwoven fabric is measured by the method mentioned later.

  Among the qualities required for a base fabric for chemical lace, one of the important factors along with the 10% modulus strength in the horizontal direction is the melting temperature of the nonwoven fabric in water. In general, the lower the dissolution temperature of the nonwoven fabric in water, the more the dye can be prevented from falling off and reattaching when the base fabric after embroidery is dissolved and removed. It becomes the most important requirement. Specifically, when the dissolution temperature in water of the PVA fiber used is A ° C., and the dissolution temperature in water of the nonwoven fabric obtained using the PVA fiber is B ° C., it is preferable that B−A ≦ 5 ° C., more Preferably, B−A ≦ 4 ° C., more preferably B−A ≦ 2 ° C. In this invention, it becomes possible to set it as B-A <= 5 degreeC by providing the aqueous solution of the foamed water-soluble PVA-type resin to a nonwoven fabric as a binder. By setting B−A ≦ 5 ° C., energy can be saved in the melting step, and a fabric for chemical lace having a soft texture can be easily obtained. When B-A exceeds 5 ° C., there is a possibility that the dye may fall off and reattach from the pre-dyed embroidery thread when the base fabric after embroidery is dissolved and removed. In particular, the conventional spraying method and impregnation method are not preferable because B-A exceeds 5 ° C., and the dye is dropped and reattached from the pre-dyed embroidery thread.

  EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited at all by this Example. In the present invention, the fiber or nonwoven fabric dissolution temperature in water, 10% modulus strength, bending resistance, and fiber strength were determined by the following methods.

(1) Fiber dissolution temperature A (° C) in water
A temperature at which several tens of mg of water-soluble fiber cut to a length of 1 to 2 mm is added to 100 cm ³ of water and heated with stirring at a heating rate of 1 ° C./min, and the fiber is completely dissolved. Was measured as the dissolution temperature A in water.

(2) Non-woven fabric dissolution temperature B (° C)
When ^three pieces of non-woven fabric or paper cut into 2 cm square are put into 400 cm ³ of water, the temperature is raised with stirring at a heating rate of 1 ° C./min and a stirring rate of 280 rpm, and the fiber is completely dissolved. Was measured as the dissolution temperature B in water.

(3) 10% modulus strength (N / 50mm width)
The nonwoven fabric is cut into 50 mm × 170 mm in the vertical and horizontal directions to make samples, and the tensile strength is measured using an Instron tensile tester under the conditions of a sample grip interval of 100 mm, a grip width of 25 mm, and a tensile speed of 100 mm / min. The intensity at% elongation was read.

(4) Bending softness (mm)
Measured by JIS cantilever 40.5 degree method.

(5) Fiber strength (cN / dtex)
Measurement was performed in accordance with JIS L1013.

Example 1
(1) PVA having a polymerization degree of 1750 and a saponification degree of 99 mol% was put into dimethyl sulfoxide (DMSO), stirred at 90 ° C. for 10 hours under a nitrogen stream at 240 rpm, dissolved, and a polymer concentration of 20% by mass. A spinning dope was obtained. The obtained spinning dope was wet-spun into a solidification bath having a mass ratio of methanol / DMSO of 70/30 and a temperature of 10 ° C. through a spinneret having 15,000 holes and a hole diameter of 0.16 mm. Subsequently, wet stretching was performed 3.0 times while extracting DMSO with an extract composed of methanol at 25 ° C. Then, it is dried at 150 ° C. for 8 minutes in a nitrogen atmosphere, stretched 2.0 times by dry heat at 170 ° C., crimped and cut, fineness of 33,000 dtex, strength of 7.2 cN / dtex, dissolved in water A PVA crimped fiber having a temperature A of 72 ° C. was obtained. The performance of the fiber is shown in Table 1.
(2) A random web composed of 100 parts by mass of the obtained PVA fiber is prepared, and an aqueous solution composed of 5% by mass of PVA same as the fiber and “BEROL-48” (linear alkylbenzene sulfonate) as a surfactant. Was foamed with a hand mixer, impregnated into the random web, and dried at 70 ° C. to obtain a nonwoven fabric. As shown in Table 2, the performance of the nonwoven fabric was as soft as 118 mm and good in workability, and further, the 10% modulus strength was as high as 27.8 (N / 50 mm width).
(3) The nonwoven fabric obtained in (2) above is embroidered with an embroidery thread made of commercially available pre-dyed polyester fiber. Met. The base fabric after embroidery has a dissolution temperature B in water of 74 ° C and B-A of 2.0 ° C. After removal, the embroidery thread had no detachment and reattachment of the dye, and an embroidery cloth with a clear and high-quality embroidery pattern was obtained.

Example 2
Spinning was carried out in the same manner as in Example 1 except that PVA having a polymerization degree of 1750 and a saponification degree of 96 mol% was used. The fineness was 850,000 dtex, the strength was 6.2 cN / dtex, and the dissolution temperature A in water was 65 ° C. A PVA crimped fiber was obtained. The performance of the fiber is shown in Table 1. Moreover, the nonwoven fabric was produced on the conditions similar to Example 1 using this fiber. As shown in Table 2, the performance of the nonwoven fabric is as soft as 86 mm and has good workability. Further, the 10% modulus strength is as high as 19.4 (N / 50 mm). When the same embroidery thread was used for embroidery, the embroidery pattern did not fly or misaligned, and it was suitable as a base fabric for chemical lace. Further, since the dissolution temperature B of the base fabric after embroidery is 68.5 ° C. and B-A is 3.5 ° C., the embroidery thread does not fall off and reattach after the base fabric is dissolved and removed. An embroidery cloth having a clear and high-quality pattern was obtained.

Example 3
(1) PVA having a polymerization degree of 1750 and a saponification degree of 98.5 mol% as a fiber raw material is added to water and dissolved by stirring at 240 ° C. for 10 hours at 90 ° C. to obtain a spinning stock solution having a polymer concentration of 17% by mass. It was. The obtained spinning solution was spun into a 40 ° C. acidic coagulation bath made of a saturated sodium sulfate aqueous solution through a spinneret having 15,000 holes and a hole diameter of 0.16 mm for coagulation. Further, the obtained shinoshino was wet-heat-stretched with a roller draft 3.0 times, washed with water, further dried at 130 ° C., then dry-heat-stretched at 170 ° C. with a draw ratio of 2.0 times, and crimped. Cutting was performed to obtain a PVA crimped fiber having a fineness of 33,000 dtex, a strength of 3.1 cN / dtex, and a dissolution temperature A in water of 76 ° C. The performance of the fiber is shown in Table 1.
(2) Furthermore, the nonwoven fabric was produced on the conditions similar to Example 1. FIG. As shown in Table 2, the performance of the nonwoven fabric was as soft as 139 mm and good in workability, and further, the 10% modulus strength was as high as 35.3 (N / 50 mm).
(3) When the non-woven fabric obtained in the above (2) was embroidered using the same embroidery thread as in Example 1, there was no embroidery pattern jumping or displacement, which was suitable as a base fabric for chemical lace. . In addition, since the dissolution temperature B of the base fabric after embroidery is 78 ° C and B-A is 2.0 ° C, the embroidery pattern does not come off from the embroidery thread after the base fabric is dissolved and removed. An embroidery cloth having a clear luxury feeling was obtained.

Comparative Example 1
As a nonwoven material, a random web similar to that of Example 1 was prepared, and the random web was impregnated with a 1% by mass aqueous solution made of the same PVA as the fiber material, squeezed, and dried at 70 ° C. to obtain a nonwoven fabric. . As shown in Table 2, the performance of the nonwoven fabric is as high as 10% modulus strength is 54.8 (N / 50 mm width), but the softness is too high at 162 mm, so the texture is hard and the same as in Example 1. An attempt was made to embroidery using an embroidery thread, but the workability was poor, such as the needle breaking during embroidery, and it was not suitable as a chemical lace base fabric.

Comparative Example 2
As a nonwoven material, a random web similar to that of Example 1 was prepared, a 1% by mass aqueous solution made of the same PVA as the fiber material was foamed, impregnated into the random web, and dried at 70 ° C. to obtain a nonwoven fabric. As shown in Table 2, the nonwoven fabric has a low 10% modulus strength of 7.8 (N / 50 mm width). When embroidering was performed using the same embroidery thread as in Example 1, the embroidery pattern jumped. -Deviation occurred and it was not suitable as a base fabric for chemical lace.

Comparative Example 3
The same random web as Example 1 was created as a nonwoven material, and the nonwoven fabric was obtained by passing between the heated embossing roll and the steel roll. The embossing conditions at this time were a bonding area ratio of 12%, a temperature of 195 ° C., a linear pressure of 329 N / cm, and a processing speed of 5 m / min. As shown in Table 2, the performance of the nonwoven fabric was embroidery, but the base fabric after embroidery had a water dissolution temperature of 86.5 ° C., and the difference from the fiber water dissolution temperature was 14.5 ° C. Therefore, when the base fabric after embroidery was dissolved and removed, the dyes dropped and reattached, which was not suitable as a base fabric for chemical lace.

According to the present invention, it is possible to provide an inexpensive chemical lace base fabric that is soft and has good workability, has high dimensional stability, is unlikely to cause embroidery pattern skipping and displacement, and has a low melting temperature, and a method for manufacturing the same. .

Claims (3)

A chemical lace base fabric comprising a random web nonwoven fabric of water-soluble polyvinyl alcohol fiber and a pre-dyed embroidery thread, which satisfies all of the following conditions.
(1) The binder to be attached to the nonwoven fabric is a foamed aqueous solution containing a polyvinyl alcohol resin, and the amount of the binder attached to the total nonwoven fabric mass is 2 to 20% by mass,
(2) The 10% modulus strength in the horizontal direction of the nonwoven fabric is 15 to 80 N / 50 mm width,
(3) The bending resistance of the nonwoven fabric is 40 to 150 mm.   B-A ≦ 5 ° C. when the water-soluble dissolution temperature of the water-soluble vinyl alcohol fiber constituting the nonwoven fabric is A ° C. and the water dissolution temperature of the random web nonwoven fabric of the polyvinyl alcohol fiber is B ° C. The base fabric for chemical laces according to claim 1.   The base fabric for chemical laces according to claim 1 or 2, wherein the water-soluble polyvinyl alcohol fiber constituting the nonwoven fabric has a dissolution temperature in water of 50 to 80 ° C.